Collapsible paperboard container and method of manufacturing the same



Apnl 3, 1956 w. FRANCK 2,740,576

COLLAPSIBLE PAPERBOARD CONTAINER AND METHOD OF MANUFACTURING THE SAME Filed May 22, 1952 2 Sheets-Sheet l IN VEN TOR.

eafer WFCZZZO/Q April 3, 1956 L. w. FRANCK COLLAPSIBLE PAPERBOARD CONTAINER AND METHOD OF MANUFACTURING THE SAME 2 Sheets-Sheet 2 Filed May 22, 1952 IN VEN TOR. leafier Wfrazzck, BY MM M Unite States COLLAPSIBLE TAPERBQARD (IQNTAINER D METHGD 8F MANUFACTURING THE SAME The present invention relates to improvements in a simple flexible paperboard container suitable for use in vending popcorn, peanuts, candy and like product, edible or not, which is not finely comminuted in character. It is a general object of the invention to provide a simple, inexpensive, throw-away type of paperboard container, which is quickly manipulated by hand to erect the same from a flat, knock-down condition to an open, article receiving condition, and which sustains itself in the last named condition.

In another aspect, it is an object of the invention to provide a flexible paperboard container, particularly a container which need not have a great deal of strength nor be a tightly sealed one, and which can be manufactured at a very high rate of speed on straight line gluing and folding equipment, due to the fact that the making of the improved container involves a straight line or longitudinal stripe gluing operation exclusively, as distinguished from a spot or transverse gluing operation.

Still more specifically, it is an object to provide an inexpensive flexible paperboard container, an improved, specially shaped and creased blank therefor, and an improved method of making the container from the blank, which feature the creasing of the blank along fold lines extending generally longitudinally of, but diverging slightly relative to, the line of advance of the blank through a conventional straight line gluing machine; the application of glue to the blank in a continuous, straight line direction paralleling its path of advance, preferably in the form of two stripes on opposite sides of two panels of the blank which are overlapped when the container is completed; and the successive folding of the blank about the fold lines referred to, whereby the glue stripes are brought into intersecting relation between the panels, extending longitudinally thereof to constitute a side wall seam for the overlapped panels, at the same time spotting together certain bottom forming panels which adjoin the side wall forming panels, the single gluing operation affording the necessary dual adhesion of two different types of container panels.

A substantial need exists for a bag-like paperboard container for use in vending popcorn and like relatively coarse particle confections or comestibles in theaters, at sporting events, and the like, which has the low cost and ease of manipulation of a simple paper bag, combined with the sturdiness and self-sustaining character of a creased and folded box. Naturally, low cost of production is a controlling factor in the commercial success of such a container, and it can be attained only by mass production manufacture at a high rate of speed.

However, no one has heretofore designed a paperboard carton of the above description which can be made on a commercial scale other than by conventional gluing and folding procedures, i. e., a gluing of a longitudinal seam stripe or area, a further separate transverse or spot gluing of a bottom seam area, and an overlapping of the glued portions in adhesively secured relation. The transverse gluing operations inherently slows down the speed "atent ice of operation substantially, with like elfect on the output of the gluer and folder. Maximum speed of output can be had, it will be appreciated, only by the use of an apparatus which applies a continuous longitudinal glue stripe or stripes alone, which will, of course parallel the path of advance of the blank being glued and folded. The provision of an improved container, a special blank, and a method of manipulating the blank to form the container, which involves only a longitudinal glue striping operation, are the essence of the present invention.

The foregoing statements are indicative in a general way of the nature of the invention. Other and more specific objects will be apparent to those skilled in the art upon a full understanding of the construction of the blank and final container, and the operation of the method in making the latter.

A single embodiment of the invention is presented herein for purpose of illustration. It will be appreciated that the invention may be incorporated in other modified forms coming equally within the scope of the appended claims.

In the drawings:

Fig. l is a top plan view of a flexible paperboard blank employed in fabricating the improved carton, illustrating the manner in which the same is died out, creased and glued as manufacture of the carton proceeds;

Fig. 2 is a top plan view showing the blank following a first fold thereof;

Fig. 3 is a top plan view of the improved carton in its completed, flat or knock-down condition, in which it is shipped or stored;

Fig. 4 is a perspective view illustrating the carton in erected condition, ready to receive its intended contents; and

Figs. 5 and 6 are, respectively, views in longitudinal and transverse cross section along lines 55 and 66 of Fig. 4.

The improved blank is generally designated by the reference numeral 10. It is of a divergent-sided, fan-like outline, featuring angular side margins 11, 12, a segiented, chordlike forward edge 13, and a rear edge M which is quite similarly segmented. Hence, economical nesting of the blanks is possible when the same are died out from a flexible paperboard sheet. The rear edge has a rectangular recess 15 adjoining side margin 11, and the purpose of this recess will hereinafter be referred to.

Inclined, generally longitudinally extending creases 16, 3'7, paralleling side margins 11, 12, respectively, subdivide the blank iii into three hingedly connected panels or sections, generally designated 18, 19 and 20, sections 18 and 20 being successively folded about those creases as the blank passes through a standard straight line gluing and folding machine. Longitudinally extending creases 21, 22, which parallel the longitudinal path of advance of the blank through the machine, subdivide the central section 19 into a rectangular side Wall panel 23 and tapered gusset panels 24, 25, which are thus hinged between the respective pairs of creasesrld, 21 and 17, 22. The creases 21, 22 are preferably cut scores in the portion'of their length extending from forward margin 13 of the 'blank to a transverse segmented cut score, generally designated 26, which outlines the bottom margin of the panels 18, 19, 22. The cut score 26 is chord-like in character, its segments paralleling the front and rear edges of the blank. The creases 21, 22 are of conventional character from the bottom forming crease or cut score 26 to the rear edge 14 of the blank. The use of cut scores to constitute certain of the creases of the blank is adopted with the object of promoting ease of automatic erection of the completed carton by the user.

A gusset panel 2''], generally similar in size and shape to the panel 24, is flexibly connected to the latter by the crease 16, and panel 27 in turn has a rear wall panel 28 hingedly articulated thereto by cut score 29 which parallels the side margin 11 of the blank. In. the same fashion, a gusset panel 30 similar to the opposite gusset panel is hinged to the latter by means of the crease 17, panel in turn having a second rear wall panel 31 hinged thereto by the cut score 32.

Bottom forming panels and gusset sections are integrally hinged by transversely extending cut score 2s to the remainder of the blank 1%, as follows: A rear bottom panel 33 adjoins rear wall panel 28; a bottom gusset section, generally denoted 34, is hinged to one pair of side gusset panels 24, 27; a front bottom panel 35 adjoins front wall panel 23; a bottom gusset section, generally denoted 36 and similar to the section 34, adjoins the pair of side gusset panels 25, 30; and a second rear bottom panel 37 adjoins rear wall panel 31.

Bottom gusset sections 34, 36 are subdivided into gusset web areas by extensions 16, 17 of the respective gusset creases 16, 17 and by the angularly related, downwardly convergent cut scores 38, 39, the former of which define the corresponding inner edges of bottom panels 33, 37. The cut scores 39 incline downwardly from the junctions of cut scores 21, 22 with cut score 26, to a meeting with cut scores 38 at a transverse segmented crease or cut score 40 paralleling crease 26. Triangular gusset webs 41, 42, 43 are outlined in gusset sections by the creasing described above.

Crease 40 serves to integrally hinge certain glue sections to the bottom panels, as follows: Glue sections 44, 45, adjoin the bottom panel 33 and web 45 of gusset section 34, respectively; a section 46 adjoins bottom panel 35; and sections 47, 48 adjoin the web 43 of gusset sec tion 36 and bottom panel 37, respectively. Glue section 44 is substantially reduced in area, as compared to the other corresponding section 48, by the recess 15, this recess exposing a substantial area of glue section 48 when the sections 44, 48 are superposed. Cut score terminal extensions 16", 17" of gusset creases 16, 17 serve to integrally hinge glue sections 44, 48 to the respective sections 45, 47.

The above described blank is completed on a standard, straight line gluing machine, the machine for completing the blank 10 being equipped with but two glue striping wheels and associated glue pots. The blank advances in a path paralleling its side wall margin creases 21, 22, with its opposite angled sides 11, 12 diverging equally in opposite directions from the line of that path. Two stripes of adhesive are applied by the striping wheels referred to, both of these stripes paralleling the path of advance. One glue stripe is designated 56, it extends diagonally of one rear wall panel 31 and its associated bottom panel 37 and glue section 48. Glue stripe 50 is applied from a top glue pot to the upper surface of the panels and section referred to, as blank 10 advances through the machine. The second glue stripe is indicated in dotted line in Fig. l and designated 51; it is applied to the lower surface of the other rear wall panel 28, extending diagonally of panel 28 and its associated bottom panel 33.

Following the application of the glue stripes 50, 51, the existing folding provisions of the gluing and folding machine come into play, swinging each of the wallgusset panels 18, 20, in succession and in the named order, about the respective gusset creases 16, 17 into superposed relation to central panel 19 and to one another. The glue stripe 51 is thus disposed on the upper surface of the partially folded blank, extending from the left hand upper or forward corner of the associated panels 18, 33 to the lower or rear right hand corner thereof. The glue stripe 50 is disposed in intersecting relation to the stripe 51, as shown in Fig. 3. Thus a very effective longitudinal seaming together of overlapped rear wall panels 28, 31 is had, including adhesion of bottom panels 33, 37 to one another. At the same time, the terminal glue section 48 is spot adhered by the lower end of stripe 59 to the glue section 46 of the opposite side wall 23, inasmuch as section 46 is exposed through recess 15. Some adhesive is also ordinarily squeezed out from the other glue stripe 51 into the area of this recess, as indicated at 52, thus to further cause glue section 48 to adhere to section 46. in effect, two glue spots are placed between the bottom glue sections, furnishing ample adhesion to seal the bottom against escape of the relatively coarse size particles of the product or substance which the improved carton is intended to receive.

The carton is erected to its operative, article receiving condition by simply squeezing the flat article at the side gusset creases 16, 17, in the zone of the bottom defining crease 26, as indicated by arrows in Fig. 3. This causes the pairs of gusset panels 24, 27 and 25, 30 to collapse inwardly, passing a flat coplanar relation of the panels of each pair and snapping past dead center to an inwardly buckled outline, in which they are automatically togglelocked against return movement.

No prebreaking of the hinge creases is required due to the use of cut scores at the various hinges as described. The carton sets up into a parallel-walled structure very convenient to handle. In this condition the carton presents a square forward lip at 53 (Figs. 4, 5 and 6) on a stiff, double-ply wall 28, 31, which is useful in scooping up popcorn, peanuts and other edible or inedible commodities rapidly from a popping or heating device, or other bin or receptacle. its bottom seal is amply strong and secure to retain bulk goods of substantial particle size, i. e., of non-powdery, non-granular character. It has the desired rigidity and body" of a paperboard or cardboard carton. It is readily erected to, and is thereafter self-sustaining in, open, article receiving condition, as distinguished from the fiimsiness of a conventional paper bag. It protects effectively against seepage, as of melted butter, which a paper bag does not, yet it can be manufactured at a cost approaching that of a paper box. This is because of the fact that the improved carton permits manufacture by straight line gluing exclusively, as distinguished from cross striping or spotting, which greatly reduces the output rate of folding and gluing equipment. The cutting away of the innermost of two wall forming panels, at the rear or bottom thereof, in order to expose another wall for adhesion to the bottom of the other of the two wall forming panels by means of an end continuation of a single, longitudinally extending glue stripe, make all this possible.

The folding operation is facilitated by the fact that the side margins of the blank are disposed symmetrically with reference to the longitudinal center line thereof and the longitudinal path of the blank through the gluing machine. However, it will be apparent to those skilled in the art that other arrangements of the blank and of the glue line than those chosen for purpose of illustration are feasible, even though possibly not quite so practical, with reference to the operation of a straight line gluing machine.

I claim:

1. A flexible paper container comprising a tubular member having front and rear wall members defined marginally by creases, one of said wall members comprising a pair of substantially overlapped wall forming panels secured in face contacting relation by means of a line of adhesive extending longitudinally of the container axis at an acute angle to at least one of said creases, said wall members including bottom terminal glue sections held in flatwise face to face adhered relation by an extension of the line of adhesive onto a bottorn glue section of the outermost of said overlapped rear wall panels, said front wall member and said outermost rear wall panel being in juxtaposed, face to face relation at said bottom terminal glue sections thereof, the innermost rear wall panel having at least a portion thereof ,Wmoved in the zone of juxtaposition of said last named glue sections and upwardly of bottom margins of the latter, said adhesive extension permanently securing said juxtaposed sections together through said removed portion.

2. A container in accordance with claim 1 in which there are two lines of adhesive securing the wall forming panels of said pair, said lines of adhesive being disposed in intersecting relation to one another.

3. A container in accordance with claim 1 in which said removed portion comprises a notch in the bottom extremity of said innermost rear wall panel which is located in inwardly spaced relation to a crease connecting the same to the front wall member.

4. A flexible paper container comprising a tubular member having front and rear wall members defined marginally by creases, one of said wall members comprising a pair of substantially overlapped wall forming panels secured in face contacting relation by means of a line of adhesive extending longitudinally of the container axis, said wall members including bottom terminal glue sections held in flatwise face to face relation by an extension of the line of adhesive onto a bottom glue section of the outermost of said overlapped rear wall panels, said front wall member and said outermost rear wall panel being in juxtaposed, face to face relation at said bottom terminal glue sections thereof, the innermost rear wall panel having at least a portion thereof removed in the zone of juxtaposition of said last named glue sections and upwardly of bottom margins of the latter, said adhesive extension permanently securing said juxtaposed sections together through said removed portion.

5. A container in accordance with claim 4 in which said removed portion comprises a notch in the bottom extremity of said innermost rear wall panel which is located in inwardly spaced relation to a crease connecting the same to the front wall member.

6. A method of manufacturing a container of flexible paperboard stock, for use in the vending of popcorn and like material, comprising forming and creasing a paperboard blank to provide a front wall panel and rear Wall forming panels integrally hinged by creases to opposed side margins of said front wall panel, advancing said blank lengthwise in the general direction of said creases, applying a continuous longitudinal stripe of adhesive paralleling said direction of advance toone of said rear wall forming panels, folding said rear wall forming panels about said creases into overlapped relation to one another, and adhering the outermost rear Wall forming panel to the innermost rear wall forming panel and to said front wall panel by means of said adhesive stripe.

7. A method of manufacturing a container of flexible paperboard stock, for use in the vending of popcorn and like material, comprising forming and creasing a paperboard blank to provide a front Wall panel and rear wall forming panels integrally hinged by divergent creases to opposed side margins of said front wall panel, advancing said blank lengthwise in a direction at an acute angle to one of said creases, applying a continuous longitudinal stripe of adhesive paralleling said direction of advance to one of said rear wall forming panels, folding said rear wall forming panels about said creases into overlapped relation to one another, and adhering the outermost rear wall forming panel to the innermost rear wall forming panel and to said front wall panel by means of said adhesive stripe.

References Cited in the file of this patent UNITED STATES PATENTS 405,413 Hicks June 18, 1889 1,070,790 Falk Aug. 19, 1913 1,279,158 Reynal Sept. 17, 1918 1,287,804 Weiss Dec. 17, 1918 1,317,687 Cooper Oct. 7, 1919 1,532,316 Kaufman Apr. 7, 1925 1,743,681 Neuman Jan. 14, 1930 2,046,483 Ringler July 7, 1936 2,202,879 Wentz June 4, 1940 2,236,060 Hyndman Mar. 25, 1941 2,400,716 Sattler May 21, 1946 

